Productivity and Quality in Smart Manufacturing Systems

Waste Reduction in Conical Taper Head Bolt Production at PT. Roller With Lean Six Sigma Method

Fajryansya Miftahul Falah and Moses Laksono Singgih


Lean Six Sigma (LSS) is an essential tool for process improvement, especially in the manufacturing industry. LSS optimizes the production process, product quality, and productivity through the Define, Measure, Analyze, Improve, and Control (DMAIC). The study discusses the conical taper head bolt because the production value is 60% of the total bolt nut set produced every month. P.T. The Rollers reached an average production rate of 2300 sets per month from the target of 3000 sets per month. One of the factors that affect production results and production lead time is waste. P.T. Roller reducing waste is LSS with the DMAIC method. This study aims to identify the causes of waste, classify waste¸ and analyze the effect of waste on the conical-taper-head-bolt production process using the DMAIC method so that the bolt-nut workshop production process runs optimally. The critical waste was waiting with an average weight of 0.292. with an inconsistency value of 0.077, the cause of waste based on analysis using Root Cause Analysis (RCA) it is known that there is a lack of evaluation of the forging mold design, lack of checking on blackening production equipment, lack of attention to the heat treatment process and experienced personnel in the field of heat treatment. The recommendations for the improvement are: to evaluate the mold design starting from material changes, changes in dimensions to changes in clamp installation so that shear and repeated welding processes do not occur, to reduce setting time by 20%, replacing the LPG regulator with a blower so that it can increase the heating speed up to 50% better than the LPG regulator and recruiting experts in the heat treatment process to redesign the system and use the sampling process to reduce waiting time in the inspection process and can reduce lead time in the process heat treatment by 50%.

Keywords: DMAIC, Lean Six Sigma, Waste


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